warning LAND ROVER DEFENDER 1999 Owner's Guide

19FUEL SYSTEM
2
ADJUSTMENT FUEL TANK - DRAIN
Service repair no - 19.55.02
1.Remove battery cover.
2.Disconnect both leads from battery, earth lead
first.
WARNING: Fuel vapour is highly
flammable and in contained spaces is also
explosive and toxic. Always have a fire
extinguisher containing FOAM, CO2, GAS OR
POWDER close at hand when handling or draining
fuel.
3.Using a fuel recovery appliance, drain the fuel
from the tank into a sealed container. Follow the
manufacturers instructions for the connection
and safe use of the appliance.
4.Remove filler cap and insert hose into filler neck.
5.Connect bowser earth line. Drain fuel.
6.Connect battery leads.
7.Fit battery cover.
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19FUEL SYSTEM
4
REPAIR ELEMENT - FUEL FILTER
Service repair no - 19.25.07
Remove
1.Release fixings and remove battery cover.
2.Disconnect battery negative lead.
3.Raise rear of vehicle.
WARNING: Support on safety stands.
4.Release fixing and remove fuel filter cover.
5.Clean area around fuel filter.
6.Disconnect multiplug from filter element.
7.Remove fuel filter element.
Refit
8.Clean fuel filter and mating face.
9.Fit new fuel filter element and connect multiplug.
10.Position fuel filter cover and secure with fixing.
11.Remove stand(s) and lower vehicle.
12.Reconnect battery negative lead.
13.Fit and secure battery cover.COOLER - FUEL
Service repair no - 19.25.30
Remove
1.Remove 3 bolts and remove engine acoustic
cover.
2.Remove battery cover.
3.Disconnect battery negative lead.
4.Drain cooling system.See COOLING
SYSTEM, Adjustment.
5.Release 3 clips and disconnect 3 coolant hoses
from fuel cooler.
6.Release 2 fuel hoses from fuel cooler.
CAUTION: Plug the connections.
7.Release vacuum pipe clip from fuel cooler.
8.Remove 4 bolts securing fuel cooler to inlet
manifold and remove cooler.
Refit
9.Clean fuel hose connections.
10.Position fuel cooler to inlet manifold. Apply
Loctite 242 to bolts and tighten to18 Nm (13
lbf.ft).
11.Connect fuel hoses.
12.Connect coolant hoses, secure with clips.
13.Secure vacuum hose to fuel cooler.
14.Refill cooling system.See COOLING SYSTEM,
Adjustment.
15.Fit engine acoustic cover and secure with bolts.
16.Reconnect battery negative lead.
17.Fit battery cover.
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19FUEL SYSTEM
12
REPAIR FUEL TANK
Service repair no - 19.55.01
Remove
1.Drain fuel tank.See Adjustment.
2.Raise rear of vehicle.
WARNING: Support on safety stands.
Vehicles fitted with tow bar
3.Remove 2 bolts securing support bars to drop
plate.
4.Loosen 2 nuts securing support bars to chassis.All Vehicles
5.Remove 2 nuts securing fuel tank support to rear
chassis member.
6.Remove 2 bolts securing fuel tank support plate
to chassis member.
7.Release clip securing filler hose and release
hose from filler neck.
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COOLING SYSTEM
1
ADJUSTMENT DRAIN AND REFILL
Service repair no - 26.10.01
WARNING: Hot coolant
Drain
1.Remove engine acoustic cover.
2.Visually check engine and cooling system for
signs of coolant leaks.
3.Examine hoses for signs of cracking, distortion
and security of connections.
4.Position drain tray to collect coolant.
5.Remove expansion tank filler cap.
6.Loosen clip screws securing air inlet hose to
intercooler and inlet manifold, release and
remove hose.
7.Release clip and disconnect bottom hose from
radiator.
8.Allow cooling system to drain.
9.Disconnect bottom hose from radiator.Refill
1.Flush system with water under low pressure.
2.Do not use water under high pressure as it could
damage the radiator.
3.Connect bottom hose to radiator and secure
hose with clip.
4.Prepare coolant to required concentration.
5.Position heater temperature control to maximum
hot position.
6.Remove bleed screw from top hose.
7.Fill system slowly through coolant expansion
tank until a steady flow of coolant is emitted from
the bleed hole in top hose.
8.Fit bleed screw to top hose.
9.Continue filling system until coolant level
reaches’MAX’mark on expansion tank.
10.Fit expansion tank filler cap.
11.Position air intake hose and tighten clip screws.
12.Start and run engine until normal running
temperature is reached.
13.If fitted, DO NOT operate air conditioning.
14.Switch off engine and allow to cool.
15.Check for leaks and top-up coolant to’MAX’
mark on expansion tank.
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CLUTCH
1
ADJUSTMENT HYDRAULIC SYSTEM - BLEED
Service repair no - 33.15.01
Check
CAUTION: Ensure the fluid in the reservoir
is maintained between the minimum and
maximum levels throughout the bleed
procedure using new brake fluid.
CAUTION: Brake fluid will damage paint
finished surfaces. If spilled, immediately
remove fluid and clean area with water.
1.Top up clutch system reservoir.
2.Raise front of vehicle and support on stands.
WARNING: Do not work on or under a
vehicle supported only by a jack. Always
support the vehicle on safety stands.
3.Remove dust cap, connect bleed tube to bleed
screw and submerge free end into a clear
container of brake fluid.
4.Loosen bleed screw, then apply steady pressure
to the clutch pedal, depressing it through its full
stroke. Allow the pedal to return unassisted.
5.Repeat the procedure until a flow of clean,
air-free fluid is purged into the container.
6.Hold pedal down and tighten bleed screw to9
Nm (7 lbf.ft).
7.Check and top up reservoir.
CAUTION: Never re-use fluid that has been
bled from the system.
8.Remove stands and lower vehicle.
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37MANUAL GEARBOX
2
ADJUSTMENT GEARBOX OIL - DRAIN AND REFILL
Service repair no - 37.24.01
Drain
1.The oil should be drained when the gearbox is
warm and the vehicle is standing on a level
surface.
WARNING: Observe due care when
draining gearbox as oil can be very hot.
2.Raise vehicle on ramp.
3.Position container to collect oil.
4.Clean area around filler/level plug.
5.Remove filler/level plug.
NOTE: Later gearboxes: Use No. 55 Torx
bit to remove filler/level plug.
6.Remove gearbox drain plug and discard sealing
washer.Refill
1.Clean gearbox drain plug and fit new sealing
washer.
2.Fit gearbox drain plug and tighten to50 Nm (36
lbf.ft).
3.Fill gearbox with correct grade of oil.See
LUBRICANTS, FLUIDS AND CAPACITIES,
Information.
4.Apply Loctite 290 to the filler/level plug and
tighten to30 Nm (22 lbf.ft).
5.Remove fluid container.
6.Lower vehicle on ramp.
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MANUAL GEARBOX
3
REPAIR LEVER - GEAR CHANGE
Service repair no - 37.16.04
Remove
1.Remove gear lever knob.
2.Release and remove gear lever gaiter(s).
3.Remove nut securing upper gear lever to lower
gear lever.
4.Remove upper gear lever from lower gear lever.
5.Using a suitable piece of tubing fitted over end of
bias spring, release both ends of bias spring
from ball pins.
6.Remove bolt and special washer securing gear
lever to housing.
7.Carefully withdraw gear lever from housing
ensuring that spring loaded nylon pad is retained
during removal.
WARNING: Personal injury may result if
nylon pad is not retained.
Refit
8.Clean gear lever, housing and nylon pad.
9.Lubricate ball pin with multi-purpose grease and
fit nylon pad and spring.
10.Depress nylon pad against spring pressure,
position gear lever in housing with the nylon pad
facing away from bias spring location.
11.Fit gear lever retaining bolt and special washer
and tighten bolt to10 Nm (7 lbf.ft).
12.Using a suitable piece of tubing fitted over ends
of bias spring, locate each end of bias spring to
ball pins.
13.Fit upper gear lever to lower gear lever and
tighten retaining nut to25 Nm (18 lbf.ft).
14.Adjust bias spring.See Adjustment.
15.Fit gear lever gaiter(s).
16.Fit gear lever knob.
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MANUAL GEARBOX
5
REPAIR
14.Remove bolt and special washer securing lower
gear lever in housing.
15.Carefully withdraw lower gear lever from the
housing ensuring that the spring loaded nylon
pad is retained during removal.
WARNING: Personal injury may result if
nylon pad is not retained.
16.Release nylon pad, recover spring.
Refit
17.Clean components, gear change housing and
mating face on remote housing.
18.Apply multi - purpose grease to ball pin and fit
spring and nylon pad.
19.Depress nylon pad against spring pressure,
position lower gear lever in housing with the
nylon pad facing away from bias spring location.
20.Fit lower gear lever retaining bolt and special
washer and tighten bolt to10 Nm (7 lbf.ft).
21.Fit upper gear lever to lower gear lever and
tighten nut to25 Nm (18 lbf.ft).
22.Drift new roll pin into housing.
23.Fit bias spring adjusting screws and locknuts.
24.Using a suitable piece of tubing, locate both
ends of bias spring over ball pins.
25.Fit new gasket to remote housing, position gear
change housing to remote housing and tighten
bolts to25 Nm (18 lbf.ft).26.Adjust bias springs.See Adjustment.
27.Fit and align tunnel cover, fit and tighten screws.
28.Secure bulkhead carpet to LH side of tunnel.
29.Position relay/fuse panel, fit spacers and tighten
screws.
30.Fit insulation pad around gear levers.
31.Fit gear lever gaiter(s).
32.Fit gearbox tunnel carpet.
33.Fit gear lever knobs.
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41 - TRANSFER GEARBOX
CONTENTS
Page
ADJUSTMENT
DIFFERENTIAL LOCK WARNING LAMP SWITCH 1.............................................
HIGH/LOW SELECTOR LINKAGE 1......................................................................
REPAIR
BOTTOM COVER - TRANSFER GEARBOX - RESEAL 1......................................
TRANSFER GEARBOX 1.......................................................................................
GASKET - REAR COVER PLATE 6.......................................................................
SWITCH - DIFFERENTIAL LOCK WARNING LAMP 7...........................................
SEAL - INPUT SHAFT 8.........................................................................................
SEAL - FRONT OUTPUT SHAFT 9........................................................................
SEAL - REAR OUTPUT SHAFT 10........................................................................
GASKET - REAR OUTPUT SHAFT HOUSING 12.................................................
SWITCH - LOW DETECT 13..................................................................................
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TRANSFER GEARBOX
1
ADJUSTMENT DIFFERENTIAL LOCK WARNING LAMP SWITCH
Service repair no - 41.20.36
Adjust
NOTE: This procedure is only necessary
for switches fitted with a locknut in place
of the threaded spacer.
1.Move differential lock selector fork to differential
locked position.
2.Connect a 12V test lamp and battery to
differential lock warning lamp switch.
3.Screw switch in until test lamp is illuminated then
screw switch in a further 1/2 turn; tighten locknut.
4.Disengage differential lock, check that test lamp
is extinguished.
5.Remove test lamp.HIGH/LOW SELECTOR LINKAGE
Service repair no - 41.20.46
Adjust
1.Disconnect battery negative lead.
2.Remove gear lever knobs.
3.Remove gearbox tunnel carpet.
4.Remove gear lever (s) gaiter.
5.Release and remove insulation pad from around
gear levers.
6.Remove 2 screws securing relay/fuse panel and
collect 2 spacers.
7.Release bulkhead carpet from LH side of tunnel
and move aside.
8.Remove 2 bolts securing hand-brake lever to
body and move aside.
9.Remove 13 screws securing tunnel cover.
10.Release and remove tunnel cover.
11.Loosen linkage locknut.
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